Molding apparatus for preparing ultra-high performance concrete using continuous fibers

Abstract

This utility model discloses a molding device for preparing ultra-high performance concrete using continuous fibers, including a fixed frame, a arranging component, a laying component, a spraying component, and a compaction component. The arranging component is disposed on the fixed frame and is used to arrange multiple strands of continuous fibers into an array structure with consistent spacing and uniform direction. The laying component is disposed on the fixed frame, with its feed end facing the discharge end of the arranging component, and is used to lay the arranged multiple strands of continuous fibers into a concrete mold. The spraying component is disposed on the fixed frame and is located on both sides of the laying component, and is used to spray cement mortar onto the multiple strands of continuous fibers laid into the concrete mold. The compaction component is disposed between the laying component and the spraying component and is used to compact the continuous fibers sprayed with cement mortar.

Description

Technical Field

[0001] This utility model relates to the field of ultra-high performance concrete molding technology, specifically to a molding device for preparing ultra-high performance concrete using continuous fibers. Background Technology

[0002] Ultra-High Performance Concrete (UHPC) is a novel concrete material with ultra-high strength, high toughness, and good durability. It is widely used in engineering fields such as high-performance structures, precast components, and infrastructure. To further improve its mechanical properties, especially its tensile strength and toughness, researchers have explored introducing various reinforcing materials into UHPC, such as steel fibers, glass fibers, polypropylene fibers, and ultra-high molecular weight polyethylene fibers. Among these, ultra-high molecular weight polyethylene fibers, due to their extremely high specific strength and specific modulus, excellent corrosion resistance, and wear resistance, have become a high-performance synthetic fiber with broad application potential.

[0003] In existing technologies, short-cut ultra-high molecular weight polyethylene (UHMWPE) fibers are typically incorporated into ultra-high performance concrete (UHVPC) to improve its mechanical properties. For example, Chinese invention patent application CN103819155A discloses "UHMWPE Fiber Concrete and its Preparation Method," which involves uniformly mixing cement, stone, sand, and silica fume, followed by the addition of small strands of dispersed UHMWPE fibers. This process can improve the tensile strength and toughness of UHVPC to some extent. However, in the aforementioned prior art, the UHMWPE fibers are incorporated into UHVPC in the form of short-cut fibers, resulting in random orientation and uneven distribution, leading to limited reinforcement and difficulty in fully utilizing the mechanical properties of the fiber material. If continuous UHMWPE fibers could be arranged in an ordered structure within UHVPC, it is expected to significantly improve the tensile strength, ductility, and crack control capabilities of UHVPC. Currently, however, there is a lack of a dedicated device and process for the orderly laying of continuous fibers and the synergistic molding of UHVPC. Therefore, it is necessary to provide a molding device for preparing ultra-high performance concrete using continuous fibers, so as to achieve efficient composite of continuous fibers and cement-based materials, thereby producing high-performance ultra-high performance concrete structural materials. Utility Model Content

[0004] The purpose of this invention is to provide a molding device for preparing ultra-high performance concrete using continuous fibers, in order to solve the technical problems of uneven distribution, random orientation, and limited reinforcement effect in existing ultra-high molecular weight polyethylene fibers incorporated into ultra-high performance concrete, which makes it difficult to fully utilize the mechanical properties of fiber materials.

[0005] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution:

[0006] This utility model provides a molding device for preparing ultra-high performance concrete using continuous fibers, comprising:

[0007] Fixture;

[0008] A layout assembly is disposed on the fixed frame. The layout assembly is used to arrange multiple continuous fibers into an array structure with consistent spacing and uniform direction.

[0009] A laying component is mounted on the fixed frame, with the feed end of the laying component facing the discharge end of the arrangement component, for laying the arranged multi-strand continuous fibers into the concrete mold.

[0010] A spraying assembly is mounted on the fixed frame and is located on both sides of the laying assembly. It is used to spray cement mortar onto the multi-strand continuous fibers laid into the concrete mold.

[0011] A compaction assembly, disposed between the laying assembly and the spraying assembly, is used to compact the continuous fibers sprayed with cement mortar.

[0012] In some embodiments, the arrangement assembly includes a roll support, a guide unit, a reversing unit, and a positioning unit. Two roll supports are respectively disposed on the top two sides of the fixed frame, and the two ends of each roll support are rotatably connected to the fixed frame. The guide unit, the reversing unit, and the positioning unit are sequentially fixed to the fixed frame from the direction near the fiber roll exit to the direction away from the fiber roll exit.

[0013] In some embodiments, the guiding unit includes a guide rod and a guide post. Two guide rods are respectively disposed at the lead-out end of each fiber roll. The two ends of the guide rods are respectively fixed to the fixing frame. A plurality of guide posts are evenly distributed on each guide rod. Each guide post has a guide hole formed at the end away from the guide rod for passing through the fiber roll wire bundle.

[0014] In some embodiments, the reversing unit includes connecting rods and rollers. Two connecting rods are arranged side by side between two guide rods. The two ends of the connecting rods are respectively fixed to the fixing frame. A plurality of rollers are evenly rotatably connected to each connecting rod and correspond one-to-one with the guide holes. The plurality of rollers on the two connecting rods are arranged alternately.

[0015] In some embodiments, the positioning unit includes a first positioning rod and a second positioning rod. The two ends of the first positioning rod are fixed to the fixing frame located below the roller, and the first positioning rod has a first positioning hole corresponding to the roller. The two ends of the second positioning rod are fixed to the fixing frame located below the first positioning rod, and the second positioning rod has a second positioning hole arranged at equal intervals.

[0016] In some embodiments, the laying assembly includes a tensioning unit and a laying unit, wherein...

[0017] The stretching unit includes a mounting base and rollers. The mounting base is fixed on the fixed frame, and the two rollers are rotatably connected to the mounting base, with the outer walls of the two rollers always in contact.

[0018] The laying unit includes tie rods and discharge heads. One end of each tie rod is fixed to the bottom of the mounting base, and the other end is fixed to both sides of the discharge head. The discharge head has multiple discharge channels corresponding to the multiple strands of continuous fibers.

[0019] In some embodiments, the compaction assembly includes a slant bar and a pressure roller. The slant bar is disposed on both sides of the laying unit and one end is fixedly connected to the pull rod. The other end of the slant bar is rotatably connected to the pressure roller. The movement trajectory of the pressure roller is located in the tangential direction of the outlet of the discharge head.

[0020] In some embodiments, the spraying assembly includes a hopper, nozzles, and a compressed air pipeline. The hopper is funnel-shaped, with its large-diameter end fixed to the mounting frame. A plurality of nozzles are disposed at the small-diameter end of the hopper. One end of the compressed air pipeline is connected to the hopper, and the other end of the compressed air pipeline is connected to an external air compressor.

[0021] In some embodiments, a moving component is further included, the moving component including a first guide rail and a second guide rail, the two ends of the second guide rail being slidably connected to the two first guide rails, the two ends of the bottom of the fixing frame being slidably connected to the second guide rail, and the fixing frame being able to move in the horizontal and vertical directions through the first guide rail and the second guide rail.

[0022] Compared with the prior art, the beneficial effects of this utility model mainly include:

[0023] The molding device provided by this invention can arrange multiple continuous fibers into an array structure with consistent spacing and direction using a set arrangement component. Then, a laying component lays the arranged continuous fibers into a concrete mold. Simultaneously, a spraying component sprays cement mortar onto the continuous fibers laid in the concrete mold. Finally, a compaction component compacts the fibers. In this way, this invention, through mechanized means, arranges multiple bundles of continuous fibers into an orderly array, and combines this with cement mortar spraying and compaction to construct ultra-high performance concrete containing continuous fibers, which can significantly improve the tensile strength and toughness of ultra-high performance concrete. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the molding device described in this utility model;

[0025] Figure 2 This is a schematic diagram of the molding device of this utility model after removing the moving components;

[0026] Figure 3 This is a schematic diagram of the structure of the arrangement component described in this utility model;

[0027] Figure 4 This is a schematic diagram of the structure of the laying component described in this utility model;

[0028] Figure 5 This is a schematic diagram of the structure of the spraying assembly described in this utility model.

[0029] Explanation of reference numerals in the attached figures:

[0030] 100. Fixture;

[0031] 200, Arrangement assembly; 201, Outlet end; 210, Roll support; 220, Guide unit; 221, Guide rod; 222, Guide post; 2221, Guide hole; 230, Reversing unit; 231, Connecting rod; 232, Roller; 240, Positioning unit; 241, First positioning rod; 2411, First positioning hole; 242, Second positioning rod; 2421, Second positioning hole;

[0032] 300. Laying component; 310. Tensioning unit; 311. Mounting base; 312. Roller; 320. Laying unit; 321. Tie rod; 322. Discharge head; 3221. Discharge channel;

[0033] 400. Spraying assembly; 410. Hopper; 420. Nozzle; 430. Compressed air piping;

[0034] 500, Compaction assembly; 510, Diagonal bar; 520, Pressure roller;

[0035] 600, Moving component; 610, First guide rail; 620, Second guide rail. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0037] To address the technical problems of uneven distribution, random orientation, and limited reinforcement effect in existing ultra-high molecular weight polyethylene (UHMWPE) fiber incorporation into ultra-high performance concrete, which makes it difficult to fully utilize the mechanical properties of fiber materials, this invention provides a molding device and method for preparing ultra-high performance concrete using continuous fibers. It has the advantages of reasonable structure, simple operation, and high molding efficiency, and realizes the efficient composite of continuous fibers and cement-based materials, thereby preparing high-performance ultra-high performance concrete structural materials.

[0038] like Figures 1-2 As shown, this utility model provides a molding device for preparing ultra-high performance concrete using continuous fibers, including a fixing frame 100, an arrangement component 200, a laying component 300, a spraying component 400, and a compaction component 500. The arrangement component 200 is disposed on the fixing frame 100 and is used to arrange multiple strands of continuous fibers into an array structure with consistent spacing and uniform direction. The laying component 300 is disposed on the fixing frame 100, and the feeding of the laying component 300 is... The end faces the discharge end of the arrangement component 200 and is used to lay the arranged multi-strand continuous fibers into the concrete mold; the spraying component 400 is disposed on the fixing frame 100 and is disposed on both sides of the laying component 300, and is used to spray cement mortar onto the multi-strand continuous fibers laid into the concrete mold; the compaction component 500 is disposed between the laying component 300 and the spraying component 400, and is used to compact the continuous fibers sprayed with cement mortar.

[0039] The molding device provided by this invention can arrange multiple continuous fibers into an array structure with consistent spacing and direction using the arrangement component 200. Then, the laying component 300 lays the arranged continuous fibers into a concrete mold. Simultaneously, the spraying component 400 sprays cement mortar onto the continuous fibers laid in the concrete mold. Finally, the compaction component 500 compacts the fibers. In this way, this invention, through mechanized means, arranges multiple bundles of continuous fibers into an orderly array and combines this with cement mortar spraying and compaction to construct ultra-high performance concrete containing continuous fibers, significantly improving the tensile strength and toughness of ultra-high performance concrete.

[0040] The following is a detailed description of each component of the molding device provided by this utility model.

[0041] In one embodiment, the fixing frame 100 is a frame structure that is wider at the top and narrower at the bottom, and the fixing frame 100 serves as the mounting carrier for the other components.

[0042] In one embodiment, such as Figure 3 As shown, the arrangement component 200 is used to arrange ultra-high molecular weight polyethylene continuous fibers into an array structure with consistent spacing and uniform direction. This structure can achieve continuous, stable, and precisely spaced fiber arrangement, providing a foundation for subsequent continuous fiber laying. Specifically, it includes a roll support 210, a guide unit 220, a reversing unit 230, and a positioning unit 240. Two roll supports 210 are respectively disposed on the top two sides of the fixed frame 100, and the two ends of each roll support 210 are rotatably connected to the fixed frame 100. The guide unit 220, the reversing unit 230, and the positioning unit 240 are sequentially fixed on the fixed frame 100 from the direction close to the fiber roll exit to the direction away from the fiber roll exit.

[0043] In one embodiment, the guiding unit 220 includes a guide rod 221 and a guide post 222. Two guide rods 221 are respectively disposed at the lead-out end 201 of each fiber roll. The two ends of the guide rods 221 are respectively fixed to the fixing frame 100. A plurality of guide posts 222 are evenly distributed on each guide rod 221. Each guide post 222 has a guide hole 2221 for passing through the fiber roll wire bundle at one end away from the guide rod 221.

[0044] In one embodiment, the reversing unit 230 includes a connecting rod 231 and rollers 232. Two connecting rods 231 are arranged side by side between two guide rods 221. The two ends of the connecting rods 231 are respectively fixed to the fixing frame 100. A plurality of rollers 232 are evenly rotatably connected to each connecting rod 231 and correspond one-to-one with the guide holes 2221. The plurality of rollers 232 on the two connecting rods 231 are arranged alternately.

[0045] In one embodiment, the positioning unit 240 includes a first positioning rod 241 and a second positioning rod 242. The two ends of the first positioning rod 241 are fixed to the fixing frame 100 located below the roller 232. The first positioning rod 241 forms a first positioning hole 2411 corresponding to the roller 232. The two ends of the second positioning rod 242 are fixed to the fixing frame 100 located below the first positioning rod 241. The second positioning rod 242 forms a second positioning hole 2421 arranged at equal intervals.

[0046] In this embodiment, five rolls of fiber material are installed on each of the two roll supports 210. The lead-out ends 201 of each roll of fiber material converge towards the center through their respective guide holes 2221 and pass around the corresponding rollers 232. The rollers 232 change the direction of the fiber bundles from horizontal to vertically downward and stretch them. Then, they are arranged in a horizontal array through the first positioning hole 2411 and the second positioning hole 2421 in sequence. The spacing between two adjacent fiber bundles is 1 cm. There are a total of 10 second positioning holes 2421, forming a standardized fiber array.

[0047] In one embodiment, such as Figure 4 As shown, the laying assembly 300 is used to continuously lay the arranged fiber array into the concrete mold and maintain tension and compaction during the laying process. This structure can ensure that the fiber array layer and the underlying cement mortar are fully bonded, improving the bonding strength between the layers. Specifically, the laying assembly 300 includes a tensioning unit 310 and a laying unit 320. The tensioning unit 310 includes a mounting base 311 and rollers 312. The mounting base 311 is fixed on the fixing frame 100, and the two rollers 312 are rotatably connected to the mounting base 311, with the outer walls of the two rollers 312 always in contact. The laying unit 320 includes a pull rod 321 and a discharge head 322. One end of the two pull rods 321 is fixed to the bottom of the mounting base 311, and the other end is fixed to both sides of the discharge head 322. The discharge head 322 has multiple discharge channels 3221 corresponding to the multiple continuous fibers.

[0048] In this embodiment, the array fiber bundle exiting from the second positioning hole 2421 enters between two rollers 312. The two opposing rotating rollers 312 clamp and stretch the fiber to ensure that the fiber maintains tension and is continuously output during the conveying process. The discharge head 322 is provided with 10 discharge channels 3221, and the spacing between each two adjacent discharge channels 3221 is 1 cm, which is used for the continuous discharge of the fiber bundle.

[0049] In one embodiment, the compaction assembly 500 includes a diagonal bar 510 and a pressure roller 520. The diagonal bar 510 is disposed on both sides of the laying unit 300, with one end fixedly connected to the pull rod 321, and the other end rotatably connected to the pressure roller 520. The movement trajectory of the pressure roller 520 is located in the tangential direction of the outlet of the discharge head 322. Thus, the pressure roller 520 can be used to compact the continuous fibers during the laying process. When the laying direction is left, the right-side pressure roller 520 is used for compaction; when the laying direction is right, the left-side pressure roller 520 is used for compaction.

[0050] In one embodiment, such as Figure 5As shown, the spraying assembly 400 includes a material hopper 410, nozzles 420, and compressed air pipeline 430. The material hopper 410 is funnel-shaped, and the large-diameter end of the material hopper 410 is fixed on the fixing frame 100. A plurality of nozzles 420 are arranged at the small-diameter end of the material hopper 410. One end of the compressed air pipeline 430 is connected to the material hopper 410, and the other end of the compressed air pipeline is connected to an external air compressor.

[0051] In this embodiment, one spraying assembly 400 is provided on each side. When the device moves to the left to lay the fibers, the nozzle 420 of the right spraying assembly 400 is activated; conversely, when the device moves to the right, the nozzle 420 of the left spraying assembly 400 is activated. The nozzle 420 is adjustable, allowing for precise control of the thickness of each layer of cement mortar according to design requirements, achieving quantitative spraying. The spraying process is synchronized with the laying process, ensuring that the fiber array bonds with the cement mortar in the shortest possible time, preventing delamination or hollow areas.

[0052] In one embodiment, combined Figure 1 As shown, the molding device further includes a moving component 600, which includes a first guide rail 610 and a second guide rail 620. The two ends of the second guide rail 620 are slidably connected to the two first guide rails 610. The two ends of the bottom of the fixing frame 100 are slidably connected to the second guide rail 620. Thus, the fixing frame 100 can move in the horizontal and vertical directions through the first guide rail 610 and the second guide rail 620.

[0053] In this embodiment, after each layer of fiber array-cement mortar composite layer is laid, the entire device moves upward on the first guide rail 610 via the second guide rail 620, and the height of the movement is equal to the thickness of the composite layer.

[0054] This utility model has the following beneficial effects:

[0055] 1. Enhances the tensile strength and toughness of concrete:

[0056] By embedding ultra-high molecular weight polyethylene (UHMWPE) continuous fibers into concrete structures in an ordered array, the tensile strength, ductility, and crack resistance of concrete can be effectively improved, which is significantly better than the traditional reinforcement method of incorporating short-cut fibers.

[0057] 2. Precise and controllable continuous fiber arrangement:

[0058] This invention employs a specially designed continuous fiber array arrangement and laying component to achieve an orderly arrangement with uniform fiber direction and controllable spacing, ensuring that the fibers are evenly distributed in the concrete according to the design direction and fully leveraging the reinforcing effect of the fibers.

[0059] 3. Simultaneous spraying and compaction processes improve interlayer bonding performance:

[0060] The cement mortar spraying component works in conjunction with the laying component to achieve simultaneous laying and spraying. The rolling device improves the interfacial bonding force between the fiber and the mortar, avoids interlayer debonding and hollowing, and enhances the overall structural stability.

[0061] 4. High degree of automation and high preparation efficiency:

[0062] This utility model device is installed on a moving component to realize reciprocating control of the fiber laying direction and layer-by-layer lifting, which is conducive to realizing multi-layer continuous production, improving molding efficiency, and is suitable for large-scale, high-quality UHPC product manufacturing.

[0063] 5. The structure is rationally designed and highly adaptable:

[0064] The device has a compact structure and reasonable layout, and can be applied to molds of various sizes and shapes. It has good prospects for industrial application, and is especially suitable for the manufacturing needs of high-strength and high-toughness concrete components.

[0065] In summary, this invention significantly improves the performance and preparation efficiency of ultra-high performance concrete by constructing a comprehensive system that integrates continuous fiber orderly arrangement, synchronous spraying and compaction, and automatic control, and has broad engineering application value.

[0066] The specific embodiments of this utility model described above do not constitute a limitation on the scope of protection of this utility model. Any other corresponding changes and modifications made based on the technical concept of this utility model should be included within the scope of protection of the claims of this utility model.

Claims

1. A molding apparatus for preparing ultra-high performance concrete using continuous fibers, characterized in that, include: Fixture; A layout assembly is disposed on the fixed frame. The layout assembly is used to arrange multiple continuous fibers into an array structure with consistent spacing and uniform direction. A laying component is mounted on the fixed frame, with the feed end of the laying component facing the discharge end of the arrangement component, for laying the arranged multi-strand continuous fibers into the concrete mold. A spraying assembly is mounted on the fixed frame and is located on both sides of the laying assembly. It is used to spray cement mortar onto the multi-strand continuous fibers laid into the concrete mold. A compaction assembly, disposed between the laying assembly and the spraying assembly, is used to compact the continuous fibers sprayed with cement mortar.

2. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 1, characterized in that, The arrangement assembly includes a roll support, a guide unit, a reversing unit, and a positioning unit. Two roll supports are respectively disposed on the top sides of the fixed frame, and the two ends of each roll support are rotatably connected to the fixed frame. The guide unit, the reversing unit, and the positioning unit are sequentially fixed to the fixed frame from the direction closer to the fiber roll outlet to the direction away from the fiber roll outlet.

3. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 2, characterized in that, The guiding unit includes guide rods and guide posts. Two guide rods are respectively disposed at the outlet end of each fiber roll. The two ends of the guide rods are respectively fixed to the fixing frame. A plurality of guide posts are evenly distributed on each guide rod. Each guide post has a guide hole formed at the end away from the guide rod for passing through the fiber roll wire bundle.

4. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 3, characterized in that, The reversing unit includes connecting rods and rollers. Two connecting rods are arranged side by side between two guide rods. Both ends of each connecting rod are fixed to the fixing frame. Multiple rollers are evenly rotatably connected to each connecting rod and correspond one-to-one with the guide holes. The multiple rollers on the two connecting rods are arranged in an alternating pattern.

5. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 4, characterized in that, The positioning unit includes a first positioning rod and a second positioning rod. The two ends of the first positioning rod are fixed to the fixed frame located below the roller. The first positioning rod has a first positioning hole corresponding to the roller. The two ends of the second positioning rod are fixed to the fixed frame located below the first positioning rod. The second positioning rod has a second positioning hole arranged at equal intervals.

6. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 1, characterized in that, The laying assembly includes a tensioning unit, which includes a mounting base and rollers. The mounting base is fixed on the fixing frame, and the two rollers are rotatably connected to the mounting base, with the outer walls of the two rollers always in contact.

7. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 6, characterized in that, The laying assembly also includes a laying unit, which includes a tie rod and a discharge head. One end of the two tie rods is fixed to the bottom of the mounting base, and the other end is fixed to both sides of the discharge head. The discharge head has multiple discharge channels corresponding to the multiple strands of continuous fibers.

8. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 7, characterized in that, The compaction assembly includes an inclined bar and a pressure roller. The inclined bar is disposed on both sides of the laying unit and one end is fixedly connected to the tie rod. The other end of the inclined bar is rotatably connected to the pressure roller. The movement trajectory of the pressure roller is located in the tangential direction of the outlet of the discharge head.

9. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 1, characterized in that, The spraying assembly includes a hopper, nozzles, and compressed air pipelines. The hopper is funnel-shaped, with its large-diameter end fixed to the mounting frame. Multiple nozzles are located at the small-diameter end of the hopper. One end of the compressed air pipeline is connected to the hopper, and the other end is connected to an external air compressor.

10. The molding apparatus for preparing ultra-high performance concrete using continuous fibers according to claim 1, characterized in that, It also includes a moving component, which includes a first guide rail and a second guide rail. The two ends of the second guide rail are slidably connected to the two first guide rails. The two ends of the bottom of the fixed frame are slidably connected to the second guide rail. The fixed frame can move in the horizontal and vertical directions through the first guide rail and the second guide rail.

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